Download INSTALLATION MANUAL

AOYG24LFC
OUTDOOR UNIT
INSTALLATION MANUAL
For authorized service personnel only.
English
INSTALLATION MANUAL
PART No. 9332809039
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AIR CONDITIONER
OUTDOOR UNIT
CAUTION
Read carefully all security information before use or install the air conditioner.
Do not attempt to install the air conditioner or a part of the air conditioner by yourself.
INSTALLATION MANUAL
9332809039
This unit must be installed by qualified personnel with a capacity certificate for handling
refrigerant fluids. Refer to regulation and laws in use on installation place.
Contents
The installation must be carried out in compliance with regulations in force in the place
of installation and the installation instructions of the manufacturer.
1.
SAFETY PRECAUTIONS .......................................................................................... 1
2.
ABOUT THE UNIT ..................................................................................................... 1
This unit is part of a set constituting an air conditioner. It must not be installed alone or
with non-authorized by the manufacturer.
3.
SELECTING THE MOUNTING POSITION ............................................................... 2
4.
INSTALLATION DIAGRAM ........................................................................................ 2
5.
INSTALLATION ......................................................................................................... 3
6.
PUMP DOWN ............................................................................................................ 4
1. SAFETY PRECAUTIONS
• Be sure to read this manual carefully before installation.
• The warnings and precautions indicated in this manual contain important information
pertaining to your safety. Be sure to observe them.
• Hand this manual, together with the operating manual, to the customer. Request the
customer to keep them on hand for future use, such as for relocating or repairing the
unit.
The unit must be correctly earthed (grounded) and the supply line must be equipped
with a differential breaker in order to protect the persons.
The units are not explosion proof and therefore should not be installed in explosive atmosphere.
This unit contains no user-serviceable parts. Always consult authorized service
personnel to repairs.
When moving, consult authorized service personnel for disconnection and installation of
the unit.
Children should be monitored to ensure they do not play with the device.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be supervised to ensure that they do
not play with the appliance.
WARNING
This mark indicates procedures which, if improperly performed,
might lead to the death or serious injury of the user.
Do not touch the aluminum fins of heat exchanger built-in the indoor or outdoor unit to
avoid personal injury when you install or maintain the unit.
CAUTION
This mark indicates procedures which, if improperly performed, might
possibly result in personal harm to the user, or damage to property.
Do not place any other electrical products or household belongings under indoor unit or
outdoor unit. Dripping condensation from the unit might get them wet, and may cause
damage or malfunction of your property.
WARNING
Never touch electrical components immediately after the power supply has been turned
off. Electrical shock may occur. After turning off the power, always wait 10 minutes or
more before touching electrical components.
Request your dealer or a professional installer to install the outdoor unit in accordance
with this installation manual. an improperly installed unit can cause serious accidents
such as water leakage, electric shock, or fire.
If the outdoor unit is installed in disregard of the instructions in the installation manual, it
will void the manufacturer’s warranty.
Do not turn ON the power until all work has been completed. Turning ON the power
before the work is completed can cause serious accidents such as electric shock or fire.
If refrigerant leaks while work is being carried out, ventilate the area. If the refrigerant
comes in contact with a flame, it produces a toxic gas.
Installation work must be performed in accordance with national wiring standards by
authorized personnel only.
Do not use this equipment with air or any other unspecified refrigerant in the refrigerant
lines.
Excess pressure can cause a rupture.
During installation, make sure that the refrigerant pipe is attached firmly before you
run the compressor. Do not operate the compressor under the condition of refrigerant
piping not attached properly with 2-way or 3-way valve open. This may cause abnormal
pressure in the refrigeration cycle that leads to rupture and even injury.
When installing and relocating the air conditioner, do not mix gases other than the
specified refrigerant (R410A) to enter the refrigerant cycle.
If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to
an abnormally high value and cause rupture, injury, etc.
For the air conditioner to operate satisfactorily, install it as outlined in this installation
manual.
Connect the indoor unit and outdoor unit with the air conditioner piping and cable
available standards parts.
This installation manual describes the correct connections using the installation set
available from our standard parts.
2. ABOUT THE UNIT
2.1. Precautions for using R410A refrigerant
WARNING
The basic installation work procedures are the same as conventional refrigerant (R22)
models.
However, pay careful attention to the following points:
Since the working pressure is 1.6 times higher than that of conventional refrigerant
(R22) models, some of the piping and installation and service tools are special. (See
the table below.)
Especially, when replacing a conventional refrigerant (R22) model with a new refrigerant
R410A model, always replace the conventional piping and flare nuts with the R410A piping
and flare nuts.
Models that use refrigerant R410A have a different charging port thread diameter to prevent erroneous charging with conventional refrigerant (R22) and for safety. Therefore,
check beforehand. [The charging port thread diameter for R410A is 1/2 inch.]
Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with
refrigerant (R22) models. Also, when storing the piping, securely seal the opening by
pinching, taping, etc.
When charging the refrigerant, take into account the slight change in the composition of
the gas and liquid phases. And always charge from the liquid phase where refrigerant
composition is stable.
2.2. Special tools for R410A
Tool name
Gauge manifold
Also, do not use an extension cable.
Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.
There is not extra refrigerant in the outdoor unit for air purging.
Using the same vacuum pump for different refrigerants may damage the vacuum pump
or the unit.
Use a clean gauge manifold, vacuum pump and charging hose for R410A exclusively.
During the pump-down operation, make sure that the compressor is turned off before
you remove the refrigerant piping.
Do not remove the connection pipe while the compressor is in operation with 2 way or 3
way valve open. This may cause abnormal pressure in the refrigeration cycle that leads
to rupture and even injury.
Contents of change
Pressure is high and cannot be measured with a conventional (R22) gauge. To prevent erroneous mixing of other
refrigerants, the diameter of each port has been changed.
It is recommended the gauge with seals -0.1 to 5.3 MPa
(-1 to 53 bar) for high pressure.
-0.1 to 3.8 MPa (-1 to 38 bar) for low pressure.
Charge hose
To increase pressure resistance, the hose material and base
size were changed.
Vacuum pump
A conventional vacuum pump can be used by installing a
vacuum pump adapter.
Gas leakage detector
Special gas leakage detector for HFC refrigerant R410A.
Copper pipes
It is necessary to use seamless copper pipes and it is desirable that the amount of residual
oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or
discolored portion (especially on the interior surface). Otherwise, the expansion value or
capillary tube may become blocked with contaminants.
As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.
Thicknesses of copper pipes used with R410A are as shown in Table1. Never use copper
pipes thinner than 0.8 mm even when it is available on the market.
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Thicknesses of Annealed Copper Pipes
Nominal
diameter
Outer
diameter
Thickness
1/4 in
6.35 mm
0.8 mm
5/8 in
15.88 mm
1.0 mm
Name
Maximum
length
Maximum height
(between indoor and outdoor)
30 m (99 ft)
20 m (66 ft)
WARNING
To install a unit that uses R410A refrigerant, use dedicated tools and piping materials
that have been manufactured specifically for R410A use. Because the pressure of
R410A refrigerant is approximately 1.6 times higher than R22, failure to use dedicated
piping material or improper installation can cause rupture or injury. Furthermore, it can
cause serious accidents such as water leakage, electric shock, or fire.
2.3. Power
• The rated voltage
Connection pipe assembly
Connection cable
Wall pipe
Decorative tape
Vinyl tape
Wall cap
Saddle
Drain hose
Tapping screws
Sealant
3. SELECTING THE MOUNTING POSITION
• Decide the mounting position with the customer as follows.
• Do not set to a place where there is oily smoke, oil is used in the factory, the unit can
contact sea breeze, sulfide gases will be generated in the hot spring area, corrosive
gases will be generated, animal may urine on the unit and ammonia will be generated
and a dusty place.
3.1. Outdoor unit
230 V AC 50 Hz.
WARNING
Before turning on the power, check if the voltage is within the 220 V -10 % to 240 V
+10 % range.
Always use a special branch circuit and install a special receptacle to supply power to
the room air conditioner.
Use a circuit breaker and receptacle matched to the capacity of the air conditioner.
Install a leakage circuit breaker in accordance with the related laws and regulations
and electric company standards.
The circuit breaker is installed in the permanent wiring. Always use a circuit that can
trip all the poles of the wiring and has an isolation distance of at least 3 mm between
the contacts of each pole.
(1) If possible, do not install the unit where it will be exposed to direct sunlight.
(If necessary, Install a blind that does not interfere with the air flow.)
(2) Do not install the unit where a strong wind blows or where it is very dusty.
(3) Do not install the unit where people pass.
(4) Take you neighbors into consideration so that they are not disturbed by air blowing into their
windows or by noise.
(5) Provide the space shown in figure so that the airflow is not blocked. Also for efficient
operation, leave open three of the four directions front, rear, and both sides.
(6) Install the unit where keep away more than 3 m from the antenna of TV set and Radio.
(7) Outdoor unit should be set to a place where both drainage and itself will not be
affected when heating.
WARNING
Install at a place that can withstand the weight of the outdoor units and install positively
so that the units will not topple or fall.
CAUTION
CAUTION
The power source capacity must be the sum of the air conditioner current and the current of other electrical appliances. When the current contracted capacity is insufficient,
change the contracted capacity.
When the voltage is low and the air conditioner is difficult to start, contact the power
company the voltage raised.
Do not install where there is the danger of combustible gas leakage.
Do not install near heat sources.
If children under 10 years old may approach the unit, take preventive measures so that
they cannot reach the unit.
4. INSTALLATION DIAGRAM
2.4. Electric requirement
INDOOR UNIT
• Electric wire size and fuse capacity:
Conductor size [mm2]
MAX.
4.0
MIN.
3.5
MAX.
2.5
MIN.
1.5
Cable
Power supply cable
Connection cable
Type
10 cm or over
Type60245 IEC57
[OUTDOOR UNIT]
60 cm or over
Type60245 IEC57
Fuse capacity (A)
30
2.5. Additional charge
Refrigerant suitable for a piping length of 15 m is charged in the outdoor unit at the factory.
When the piping is longer than 15 m, additional charging is necessary.
Between 15 m and 30 m, when using a connection pipe other than that in the table, charge
additional refrigerant with 20 g/1 m as the criteria.
10 cm or over
30 cm or
over
30 cm or over
For the additional amount, see the table below.
15 m
None
20 m
+100 g
25 m
+200 g
30 m
+300 g
Rate
20 g/m
CAUTION
5 cm or over
When adding refrigerant, add the refrigerant from the charging port at the completion
of work.
Outdoor
unit
bottom
The maximum length of the piping is 30 m. If the units are further apart than this, correct
operation can not be guaranteed.
Drain Drain cap
pipe
2.6. Accessories
The following installation accessories are supplied.
Use them as required.
Drain cap
Drain cap
Drain pipe
1
• Do not directly install it on the
ground, otherwise it will cause
failure.
• To obtain better operation efficiency, when the outdoor unit
is installed, be sure to open the
front and left side.
Installation manual
3
54 cm
1
32 cm
Pipe length
Additional refrigerant
One set of following parts are necessary installation of this product.
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CAUTION
When the outdoor temperature is 0 ˚C or less, do not use the accessory drain pipe
and drain cap. If the drain pipe and drain cap are used, the drain water in the pipe may
freeze in extreme cold weather. (Reverse cycle model only)
Connection cable wiring
Run the connection cable to the rear of the outdoor unit within the A range of the arrows shown in the figure.
(The connector cover becomes difficult to install.)
In the area with heavy snowfall, if the intake and outlet of outdoor unit is blocked with
snow, it might become difficult to get warm and it is likely to cause of the breakdown.
Please construct a canopy and a pedestal or place the unit on a high stand (local
configured).
Connection cable
Hole
8 cm
A 10 cm
How to fixed connection cable and power supply cable at the cable clamp
5. INSTALLATION
After passing the connection cable and power supply cable through the insulation tube,
fasten it with the cable clamp.
Insulation tube
5.1. Outdoor unit installation
 Set the unit on a strong stand such as thing made of concrete blocks to minimize shock and vibration.
 Do not set the unit directly on the ground because it will cause trouble.
WARNING
Insulation tube
Install the unit where it will not be tilted by more than 5°.
Cable clamp
When installing the outdoor unit where it may exposed to strong wind, fasten it securely.
Use VW-1, 1.0 mm thick, PVC tube as the insulation tube.
5.2. Connector cover remove
Connector cover removal
5.4. HOW TO CONNECT THE WIRE TO THE TERMINALS
● Remove the tapping screws.
Connector cover
Installing the connector cover
Tapping screw
Hooks
(1) After inserting the four hooks, then push
upward.
(2) Tighten the tapping screws.
Tapping screw
5.3. Outdoor unit wiring
(1)
(2)
(3)
(4)
(5)
(1) Use crimp-type terminals with insulating sleeves as shown in the figure below to connect to the terminal block.
(2) Securely crimp the crimp-type terminals to the wires using an appropriate tool so that
the wires do not come loose.
(3) Use the specified wires, connect them securely, and fasten them so that there is no
stress placed on the terminals.
(4) Use an appropriate screwdriver to tighten the terminal screws. Do not use a screwdriver that is too small, otherwise, the screw heads may be damaged and prevent the
screws from being properly tightened.
(5) Do not tighten the terminal screws too much, otherwise, the screws may break.
(6) See the table below for the terminal screw tightening torques.
Tightening torque
Remove the outdoor unit connector cover.
Bend the end of the cable as shown in the figure.
Connect the end of the connection cable fully into the terminal block.
Fasten the sheath with a cable clamp.
Install the connector cover.
M4 screw
1.2 to 1.8 N • m (12 to 18 kgf • cm)
M5 screw
2.0 to 3.0 N • m (20 to 30 kgf • cm)
Strip
10 mm
Crimp-type terminal
Cable clamp
Connection cable
Sleeve
Screw with special washer
5mm
12mm
Crimp-type terminal
Terminal board
Terminal block
20mm
12mm
5mm
20mm
30mm
Earth
screw
5mm
12mm
3 L N
20mm
1 2
12mm
5mm
Wire
Screw with special washer
Crimp-type terminal
Wire
CAUTION
Cable clamp
Connection cable
Indoor unit terminal block
Earth screw
1 2
Power supply cable
Outdoor unit terminal block
3
1 2
3 L N
Earth screw
Connection cable
Match the terminal block numbers and connection cable colors with those of the indoor
unit.
Erroneous wiring may cause burning of the electric parts.
Connect the connection cables firmly to the terminal block. Imperfect installation may
cause a fire.
Always fasten the outside covering of the connection cable with the cable clamp. (If the
insulator is chafed, electric leakage may occur.)
Securely earth the power cable plug.
Do not use the earth screw for an external connector. Only use for interconnection
between two units.
Power supply cable
5.5. Connecting the piping
CONNECTION
(1) Install the outdoor unit wall cap (supplied with the optional installation set or procured at the site) to the wall pipe.
(2) Connect the outdoor unit and indoor unit piping.
(3) After matching the center of the flare surface and tightening the nut hand tight,
tighten the nut to the specified tightening torque with a torque wrench. (Table 1)
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FLARING
Check if [L] is flared uniformly and
is not cracked or scratched.
(1) Cut the connection pipe to the necessary
length with a pipe cutter.
(2) Hold the pipe downward so that cuttings will
not enter the pipe and remove the burrs.
(3) Insert the flare nut onto the pipe and flare the
pipe with a flaring tool.
Insert the flare nut (always use the flare nut
attached to the indoor and outdoor units
respectively) onto the pipe and perform the flare
processing with a flare tool.
Use the special R410A flare tool, or the
conventional (for R22) flare tool.
When using the conventional flare tool, always use
an allowance adjustment gauge and secure the A
dimension shown in table 2.
3-way valve
Gauge manifold
Compound pressure gauge
Pressure gauge
-0.1 MPa
2-way valve
(-76 cmHg
Flare nut
-1 bar)
High
Low pressure
pressure
side valve
side valve
(closed)
Valve stem
Die
Blank cap
A
Charge
hose
Charge hose
Charging port
Pipe
Charging port cap
BENDING PIPES
(1) When bending the pipe, be careful not to crush it.
(2) To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 70 mm or over.
(3) If the copper pipe is bend the pipe or pulled to often, it will become stiff. Do not
bend the pipes more than three times at one place.
Vacuum pump
Tightening torque
Blank cap (2-way valve)
Blank cap (3-way valve)
Charging port cap
20.0 to 25.0 N • m (200 to 250 kgf • cm)
28.0 to 32.0 N • m (280 to 320 kgf • cm)
12.5 to 16.0 N • m (125 to 160 kgf • cm)
Holding spanner
5.7. TEST RUN
Body side
90°
Torque wrench
Table 1
To prevent gas leakage, coat the flare
surface with refrigerator oil.
Flare nut tightening torque
Flare nut
6.35 mm dia.
15.88 mm dia.
Table 2
Diameter (mm) x Torque (N • m)
17 x 16 ~ 18
26 x 63 ~ 75
Pipe outside diameter
Pipe outside
diameter
Flare tool for
R410A, clutch type
ø 6.35 mm (1/4")
ø 15.88 mm (5/8")
0 to 0.5
0 to 0.5
A (mm)
Conventional (R22) Flaring tool
Clutch type
Wing nut type
1.0 to 1.5
1.5 to 2.0
1.0 to 1.5
1.5 to 2.0
 Perform test operation and check items below.
 For the test operation method, refer to the operating manual.
 The outdoor unit, may not operate, depending on the room temperature. In this case,
press the TEST RUN button on the remote controller while the air conditioner is running,
(Point the transmitter section of the remote controller toward the air conditioner and
press the TEST RUN button with the tip of a ball-point pen, etc.)
 To end test operation, press the remote controller START/STOP button.
(When the air conditioner is run by pressing the TEST RUN button, the OPERATION
indicator lamp and TIMER indicator lamp will simultaneously flash slowly.)
OUTDOOR UNIT
(1) Is there any abnormal noise and vibration during Transmitter section
operation?
(2) Will noise, wind, or drain water from the unit
disturb the neighbors?
(3) Is there any gas leakage?
TEST RUN button
CAUTION
Fasten a flare nut with a torque wrench as instructed in this manual. If fastened too
tight, the flare nut may be broken after a long period of time and cause a leakage of
refrigerant.
5.6. Air purge
Always use a vacuum pump to purge the air.
Refrigerant for purging the air is not charged in the outdoor unit at the factory.
Close the high pressure side valve of the gauge manifold fully and do not operate it during
the following work.
CAUTION
Refrigerant must not be discharged into atmosphere.
After connecting the piping , check the joints for gas leakage with gas leak detector.
(1) Check if the piping connections are secure.
(2) Check that the stems of 2-way valve and 3-way valve are closed fully.
(3) Connect the gauge manifold charge hose to the charging port of the 3-way valve (side
with the projection for pushing in the valve core).
(4) Open the low pressure side valve of the gauge manifold fully.
(5) Operate the vacuum pump and start pump down.
(6) Slowly loosen the flare nut of the 3-way valve and check if air enters, then retighten
the flare nut.
(When the flare nut is loosened the operating sound of the vacuum pump changes
and the reading of the compound pressure gauge goes from minus to zero.)
(7) Pump down the system for at least 15 minutes, then check if the compound pressure
gauge reads -0.1 MPa (-76 cmHg, -1 bar).
(8) At the end of pump down, close the low pressure side gauge of the gauge manifold
fully and stop the vacuum pump.
(9) Slowly loosen the valve stem of the 3-way valve. When the compound pressure
gauge reading reaches 0.1-0.2 MPa, retighten the valve stem and disconnect the
charge hose from the 3-way valve charging port.
(If the stem of the 3-way valve is opened fully before the charge hose is disconnected, it may be difficult to disconnect the charge hose.)
(10) Fully open the valve stems of the 2-way valve and 3-way valve using a hexagon
wrench. (After the valve stem begins to turn, turn it with a torque of less than
2.9 N • m (30 kgf • cm) until it stops turning.)
(11) Firmly tighten the 2-way valve and 3-way valve blank cap and the charging port cap.
5.8. CUSTOMER GUIDANCE
Explain the followings to the customer in accordance with the operating manual:
(1) Starting and stopping method, operation switching, temperature adjustment, timer,
airflow switching, and other remote controller operations.
(2) Air filter removal and cleaning, and how to use the airflow direction louvers.
(3) Give the operating and installation manuals to the customer.
6. PUMP DOWN
6.1. Pump down
PUMP DOWN OPERATION (FORCED COOLING OPERATION)
To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal,
recover refrigerant by doing the cooling operation or forced cooling operation according
to the following procedure. (When the cooling operation cannot start in winter, and so on,
start the forced cooling operation.).
(1) Do the air purging of the charge hose by connecting the charging hose of gauge manifold to the charging port of 3-way valve and opening the low-pressure valve slightly.
(2) Close the valve stem of 2-way valve completely.
(3) Start the cooling operation or following forced cooling operation. Keep on pressing the
MANUAL AUTO button of the indoor unit for more than 10 seconds. The operation indicator lamp and timer indicator lamp will begin to flash simultaneously during test run.
(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on
pressing for more than 10 seconds.)
(4) Close the valve stem of 3-way valve when the reading on the compound pressure
gage becomes 0.05~0 Mpa(0.5~0 kg/cm2).
(5) Stop the operation.
• Press the START/STOP button of the remote control unit to stop the operation.
• Press the MANUAL AUTO button when stopping the operation from indoor unit side. (It
is not necessary to press on keeping for more than 10 seconds.)
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